Process and apparatus for the manufacture of paper products



s sheets-sheet 1 I I I I l April 5, 1938. H. A. ELLIS El AL PROCESS AND APPARATUS FOR THE MAKUFACTURE OF PAPER PRODUCTS April 5, 1938.

H A. ELLIS ET AL 2,113,297 PRbcEsS AND APPARATUS FOR THE MANUFACTURE OF PAPER PRODUCT-S I Filed A rifs, 1955 '5 SI eetS-Sheet 2 April 5, 1938. H. A-.4ELI IS E+ AL 2,113,297 PRbcEss AND APPARATUS FOR THE MANUFACTURE OF PAPER PRODUCTS 5' Sheets-Sheet 3 Filed April s, 1953 April 5, 1938. I H. A. ELLISV ET AL 2,113,297

PROCESS AND APPARATUS FOR THE MANUFACTURE OF BAPER PRODUCTS Filed April- 3, 1933 5 Sheets-Sheet 4 April 5 1938.

H. A. ELLIS ET AL PROCESS AND APPARATUS FOR THE MANUFACTURE OF PAPER PRODUCTS 7 Filed April 5, 1953 5 Sheets-Sheet 5 1 VE NTOR. I

Patented Apr. 5, 1938 v PATENT oFFicF' PROCESS AND APPARATUS For: 'rnr: MANU morons or PAPER PnomJo'rs Henry A. Ellis, Sharonviile, and William A. Slattery, Hamilton, Ohio, asslgnors to The Philip- Carey Manufacturing Company, a comration of Ohio Application April 3, 1933, Serial No. 664,148

19 Claims.

This invention relates to the process and apparatus for the manufacture of paper products, being more particularly concerned with the production of that type of paper stock known as felt paper stock, such as is used in the manufacture of roofing products, felt backed floor coverings, and other kindred felt paper products wherein this type of paper stock is used.

The invention consists in the features, combinations and compositions hereinafter described or claimed for carrying out the above stated object and such other objects as will hereinafter appear.

One of the objects of the invention is to procure rapid preparation of the felting stock, the elimination of a large number of heaters, and other economies, as will more definitely appear hereinafter in the description.

The raw stock for felt paper manufacture usually consists of a variety of textile stocks;

a ball, and the knots incident to the presence of string and rope stocks of various kinds and otherwise.

A felt paper stock machine requires the presence of several breaker beaters, dependent upon tonnage. For the purpose of comparison, let it be assumed that a felt paper stock machine line has a tonnage requiring the presence of four breaker heaters, to which the" raw cut stock is supplied by stock cutters and conveyor systems.

as is usual. These beaters beat or break the stock for a sumcient time for the stock to become thoroughly saturated with the water and have most of the knots reduced, and then the stock is dumped into a series of stock chests from which it is pumped to a series of finishing heaters, usually about twelve in number, where the stock is reduced to the required degree of fiber content, and

stored in a second series of stock chests, from which the stock is drawnas needed and subjected to further refining, if desired, in the usual Jordan engine, and then passed-to the paper machine to be made into felt paper stock. In the treatment by many beaters, which has heretofore been necessary; the length of the fibers was greatly reduced, thereby affecting the strength of the sheet, its absorbing quality, and its compactness, and otherwise reducing the desirable qualities in a felted sheet used for roofing, floor covering, heat insulation, sound deadening, and other like purposes. I

By the use of this process as manyas two of the breaker heaters and as many as twelve of the finishing beaters may be eliminated, and yet a better, softer and longer fiber stock is produced, resulting in a felt paper stock with a high degree of permeability and of greatly increased strength.

For a better understanding of this improved process and apparatus for carrying out same reference may be had to the accompanying drawings, in which:-- g

Figure 1 is a diagrammatic, longitudinal sectional view of a series-of felt paper stock cutters and a conveying system between the cutters;

Figure 2 is a diagrammatic, longitudinal sectional view of a breaker beater;

* Figure 3 is a diagrammatic, transverse sectional view of a paper stock storage chest;

Figure '4 is a side elevation view of a double acting, plunger type stock pump;

Figure 5 is a front elevation of a dehydrating apparatus;

Figure 6 is an elevation view of a fsave all tank;

Figure 7 is a diagrammatic sideelevation view of a rod mill and its driving and discharging connections;

Figure 8 is a side elevation view of a single acting stock pump for discharging the stock to. a head box at an elevated level; n

Figure 9 is a diagrammatic, longitudinal sectional view of a continuous stock beater and its output control box;

Figure 10 is a transverse sectional view of a pair of stock storage chests; I

Figure 11 is a side elevation ofa double acting stock pump, for discharging the stock from the stock storage chests into a Jordan engine;

Figure 12 is a side elevation of a Jordan engine into which the stock'is pumped from the stock storage chests; v

Figure 13 is a side elevation of a double acting stock pump connected from a stock chest toa" machine stock-chest and a machine head box;

Figure 14 isa diagrammatic side elevation of amachine head box; Figure 15 is a diagrammatic, longitudinal view,

stock;

.Figure 19 is an extended plan view of one of the screen and tray members of the dehydrator; Figure 20 is a longitudinal sectional view of the rod mill shown in Figure 7, the section being on line A--A of Figure 21;

Figure 21 is a transverse sectional view of the rod mill, the section being on line 3-3 of Figure 20; and

Figure 22 is a plan view of the adjusting device for the screen and tray members of the dehydrator.

It will be understood that the word stock, as used in describing the product of the various instrumentalities of the process, refers to the conglomerate, fibrous mass or mix that goes to make up the finished felt paper stock of the process. Therefore, the term stock may refer to both the dry and the wet conglomerate or fibrous mass. Previous to the time that it is fed to the breaker beater it is in a-dry state, but is in a wet condition from that beater until the sheet is formed to take off the end of the machine.

Referring to the drawings (Figure 1) numeral I designates a delivery spout from which the stock is fed from a supply room to a conveyor 2 by which it is delivered to the rag cutter-4, the stock being fed to the rag cutter knives by feed rolls 5, which are mounted near one end of. the conveyor. -'I'he rag cutter 4 is driven at the desired speed by a motor 6. The stock from rag cutter 4 is deposited upon a conveyor belt I, which carries the cut stock to a second rag cutter 3, similar to cutterl. This second rag cutter 8 further reduces the size of the stock. The second cutter delivers the out stock to a conveyor 9, which in turn deposits it to a breaker beater l0 (Figure 2). There are some types of fiber which do not need to be subjected to the cutting devices, and this may be fed directly to the breaker beater l0, or at some preliminary point, such as the conveyor 9, which will deposit the stock into the breaker beater. The breaker beater may with some stock be omitted except for mixing the stock with water. This beater tends to not only mix the materials but also reduces the length of the fibers which it is desirable to avoid.- Therefore,

when it is dispensed with, the knives are adjusted so as to'prevent cutting of fibers. Breaker beater I0 typifies a beater having tub II and adjustable rotating knife bar roll l2, which contacts with the' bed plate bars |3. This breaker beater ID has provision (not shown) for supplying water to the stock delivered therein. The operation of cutters 4 and 3 is preferablyintermittent, being operated for a time long enough to flll the breaker beater lll to the desired level. The breaker beater operates upon the stock with-the roll l2 in light contact with the bed plate [3, and circulates the stock until same is thoroughly saturated with water. In the meantime roll l2 in its contact with bed .plate |3 reduces the knots which arecontained in the stock. As has been previously into knots and were not broken up by the cutter knives, and any other material, small pieces of which are in thicknesses or tangled knots.

When the stock has been thoroughly moistened with the water and the knots reduced to somewhat near the condition of the remainder of the stock, the prepared batch of stock is then dumped by means of a valve I4, in pipe I5, connected to the tub ll of the breaker beater I0, into a stock chest l6 (Figure 3) where the fiber content of the stock is kept in suspension by agitator I1.

While we have described that the cutters are op erated intermittently and that the breaker beater is a batch beater, it will be understood that these mechanisms may be .so regulated in respect to the other parts of the machine hereinafter described, that they may operate continuously as distinct from intermittently.

During the time that the stock is in breaker beater In large quantities of water is. absorbed by it, and an excess amount of water is added to the mass of stock in the breaker beater in order to provide rapid circulation of the stock around the beater tub and around the knife roll, thus rapidly reducing the knots. After this object has been accomplished it is desirable that some of the water in and combined with the stock be head box and chute body. This partition 23 may preferably be composed of bars 25, held in position by guide strips 28 secured to the casing, thereby making" it possible to lift or lower the height of the partition 23 by adding additional barsor removing bars therefrom, and thus main-" tain a desired head of stock'in compartment 21 of the head box, the excess flowing over partition 23 and being returned by pipe 28 to stocko chest Ii.

Within the body of the dehydrator chute 2|, just below the discharge opening 24, there is provided a sloping screen plate 29, which may advantageously be composed of thin, flat bars set on edge and separated by separators as shown at '30', in Figure 19. At the top and bottom of screen plate 23 assembly rods 3| extend beyond the screen plate and pass beyond .the walls of the.

chute body, and are secured in place by nuts 32 (Fig. 5). Secured to the upper edge of the'sloping screen plate is an apron 33 of waterproof material, such as rubber, the purpose of which will be ,hereinafter described.

Directly below screen plate 29 and sloping in the opposite direction is a second screen plate 34. This screen plate may be of the same con struction as screen plate 23, except that the rod at the lower end does not extend through the chute walls but is shortened .and forms a pivot 36 for a tray or a trough 35, as is seen in Figures 18 and 19. The tray 35 is'disposed in a directlon opposite to. that of screen plate 34, with its outer or free end projecting through an opening 31, in the wall of the chute body 2|.

Secured to either side of tray 35, at the free end thereof, are adjusting screws 38, which extend outward and pass through the outer wall of the discharge box 39. The discharge box is secured to the chute body 2| below theopening 31,

and is adapted to receive material discharged y4| having holes in them for the passage of the adjusting screws 38.

Mounted on the adjusting screws are hand nuts 42, these hand nuts bearing on one side against the discharge box and on the opposite side against the resistance bar 42. This arrangement makes'it possible to adjust the angle of the screen plate 29, by the turning of the hand nuts 42 on the adjusting screws 38.

The discharge box 39, has secured to its bottom portion a discharge pipe 43, this discharge pipe emptying in a second discharge box having a discharge pipe 45, which empties into a save all tank 46, Figure 6.

As is shown in Figures 5 and 18, there is a second series of discharge boxes 41, and discharge pipes 48, on the side of the chute body 2| opposite that which haspreviously been described, the lower discharge pipe 48 of this series discharging into save all tank 46.

As is seen in Figure 18, there is within the chute body 2| a series of sloping screens and their discharge trays 49, '50 and 5|, the component parts of thesescreensbeing the same as those described for screen 34, its tray and adjusting members. Therefore, it is to be understood that detailed description of the opera-' .proper head", it fiows out of opening 24 and falls upon the apron 33 of sloping, fixed screen plate 29, the apron 33, preventing the heavier and larger portions of the stock from wedging themselves between the screen bars and thus clogging them.

Due to the slope of screen 29, the heavier stock slides downward upon the screen, the portions fine enough to do so passing through the screen bars with someof the water and falls upon screen 34, through which the water and fine stock pass and fall upon tray from which they flow to discharge box 39. From there they pass downward through discharge pipe 43, to discharge box 44 and then by discharge pipe pass to the save all tank 46. The heavier portions of the stock, sliding down screen 29, fall upon the apron 33 of adjustable screen 34 and more of the water and fine stock pass through .the bars of screen 34 and fall upon tray 35 by means of which they are discharged as above described.

Looking at Figure 18, it is seen that disposed in zig-zag fashion below screen 34, are screens 49, 56 and 5|, these screens being of the same construction as screen 34, with its apron 33 and tray 35. i

As the heavier portions of the stock slide down the bars of screen 34, they fall upon screen 49 and thence to screen 56 and then to screen 5|.

, Each of these series of. screens removes some of the finer portions of the stock and most of the water, discharging the separated finer portions of stock and water into discharge boxes 39 and, 41 and by pipes 45 and 48 to the save all tank 46.

The degree of dehydration of the stock may be regulated by the adjustment of the slope of the screens, this adjustment being effected by the adjusting screws 38 and hand nuts 42, as has been described. The greater the pitch of the screens, the faster the stock will travel downward through the dehydrator chute,- withconsequent reduction in dehydrating; the lesser the pitch, the slower the travel for the stock and the consequent increase in dehydration. It is therefore possible to regulate the moisture content in the heavy stock being discharged into the bottomof the dehydrator chamber, by adjusting the screen members to various degrees of angularity. The dehydrated stockfalling into the bottom of the chamber of the dehydrator, passes into discharge pipe 52 and is delivered toa rod mill ing the length of the fibers, accomplishing these results in a continuous operation upon stock carrying a relatively small amount of moisture and with a comparatively slow travel through the mill.

* Referring now to Figures 7, 20 and 21, in which there is shown a rod mill, the constructionconsists of a steel shell 53, carried for rotation by a pair of circular ,tracks 54 bearing on a set of bearing rolls 54. The mill may be driven by a motor and gear reduction unit, as at 55, the driving gear 56 meshing in driving relationship with a ring gear 51 which is secured to the outer portion of the shell 53 near its center of length. The interior of the shell 53 is lined with wood as a cushioning medium and this is followed by a hardened corrugate steel lining 58, the ends of the shell being lined with smooth tapered steel sections 59. Projecting into the left end (Figure 20) of the shell53, is a. nipple 68, being a co tinuation of discharge pipe 52, this nipple having a running fit in the extension 6| of shell 53.

At the right end of the shell 53 is atapered discharge opening 63. A discharge chamber 64 is carried on a stand 65 and has a running jointure with the exterior of shell 53. Carried by this discharge chamber 64 is a tapered disc 66, which projects into tapered discharge opening 63, and is capable of adjustment towards and away from the discharge opening 63, thus providing a control for the rate of discharge of the stock from chamber 61 of the rod mill 68.

There is disposed (Figures 20 and 21) loosely within the chamber 61 of the rod mill 68, a number of elongated rods 69, which may advantageously be of various diameters, in actual practice varying from of an inch to 3 inches in diameter or more, and these rods are adapted, as the shell 53 of the rod mill turns under the in- 4 fluence of its driving unit 55, to tumble or cascade over and over.

As this tumblingof the rods occurs the moist stock, which has been introduced into the rod. mill 68 by pipe 52 from the dehydrator, is caught by the cascading rods, and the fibers are without cutting drawn out and separated. Knots which were partially reduced in the breaker beater M,- are quickly drawn out into a plurality of indethe mass of fibrous pulp stock works its way towards the discharge opening 63 and is discharged into chamber 64 from which it is discharged through spout (it into -a head box 64'" from which it is pumped by any suitable means, such as a single action plungerpump Ill, through conduit line Hi to a head box 10 (Figure 9).

Any excess stockover the capacity of the head box 10* returns through pipe II to stock chest IS.

The stock in head box 10 is used to supply continuous mixing and finishing beater 12, through pipe-12 the quantity going to the beater being controlled by valve 13. Heavy consistency stock is drawn from head box 10 into continuous mixing and finishing beater 12, where additional water is added and the stock is distributed and drawn out into a felting pulp by roll 14 and bed plate 15.- v

The back fall plate of the continuous mixing and finishing beater 12 may advantageously be perforated with a large number of holes 16, the size of these holes being determined by the degree of fineness desired in the stock, the finer portions of the stock passing through holes I6 and into a compartment formed in the back fall, from which the stock fiows by pipe 16 to control box 11, which is provided with an adjustable partition .18, the lower member of which has secured to it a handle 19, which extends above the top of the control box in a position to be grasped by the operator.

By adding sections 80, above the one secured to handle I9, the head in the continuous beater may be increased or, conversely, reduced by moving one or more of the sections 80. If for any reason it be desired to reduce the head quickly in continuous beater 12, the operator pulls handle I9 upward, lifting the'entire partition structure and allowing the stock from the continuous beater to fiow directly into discharge pipe 8| and then to one or the other of any number of stuff chests 82 (Figure 10). The. maintaining of a high head in the continuous finish beater insures a thorough reduction of the stock. The loss of stock through the continuous discharge of the finer portions through head box 11 into the stuff chests 82 is compensated for by a properly regulated continuous replacement of stock from the,

head box 10.

From the stuff chest 82 the stock is pumped by 4 any suitable means, typified by a double acting plunger pump 83, (Figure 11), through pipe 8!, to a Jordan refining engine 85 (Figure 12), from which the stock is carried by discharge pipe 86 to-the machine stuff chest 81. Use of the-Jordan refining engine is optional in the system, de-

pendent upon whether or not it is desired to refine the stock further. If it is not desired to further refine the stock, the Jordan refining engine may be eliminated, in which case the stock felt papersheet is formed and enters the dryers of paper machine, thereis diagrammatically shown in Figures 15, 16 and 17 a typical single cylinder felt paper machine which will be briefly described.

After the stock reaches head box 90 there may be mixed therewith some of the stock from the save all chest 46, in order to increase the water content and have the stock at the proper consistency for felting. Any suitable means (not shown) may be employed for feeding the save all stock to the stock in head box 90.

The stock in the head box 90, having had added the necessary water from the save all or white water chest, is now discharged by spout 9| to screens 93, from which the stock after passing through the screens 83 fiov's into control box 94 and then to flow box 85. The stock then passes on to forming cylinder '91 from which it is picked off by felt 98 and passes over suction boxes 99; and through the suction rolls I80, by

which all of the removable water has been extracted and thesheet formed. From the suction rolls Hill, the formed sheet (is carried by the felt to the first press rolls II, where the sheet leaves the firstfelt '98, and is taken up by the second felt I02, and carried through the second press rolls I03, from which the now fully formed sheet of felt paper stock Illl is led over the baby drier I05, and started on its travel through the dryers I08 in theusual manner, and, after passing from the dryers the felt paper sheet is wound on to the usual rolls for further disposal.

The above described process and apparatus are not only important factors in effecting great economies in time, labor and expense, but they are of even greater importance in processing stock which produces a felted sheet of improved quality, character and texture. r The resulting sheet of greater bursting, tearing and tensile strength, is more uniform in character, is more flexible and pliable, and has a greater absorbing ,quality than sheets heretofore made. Heretofore to supply stock for given tonnage of a paper machine, it has required four breaker beaters, twelve finish heaters and one-Jordan refining'engine, andfor supplying this same paper machine our process and apparatus require at most only two breaker 'beaters, one rod mill and two finish beaters. Of the Jordan refining engine the breaker heaters and the finishing beaters, one or more as desired depending upon the character of the stock being used to prepare the felting pulp, may or may not be used.

While we have described the process and apparatus in detail, it will be understood that such detailed construction is for the purpose of illustration and not as a limitation of the invention.

Various changes may be made in details of construction without departing from the spirit of the invention. v What we claim and desire to'secure by Letters Patent is:

- 1. The method of preparing pulp to be used in forming felted sheets comprising separating the fibers of textilematerial by beating and subjecting same to the action of a plurality of cylindrical rods assembled so as to readily roll over each other under their own weight, wherebythe fibrousmaterial is separated into individual fibers without materially reducing the length of same.

2. The method of preparing pulp for the manufacture of rag felt comprising beating textile material in th e, presence of a liquid and feeding the beaten material and liquid into a rotating mill containing cylindrical rods arranged so that .the rods rotate on their longitudinal axis parallel to the rotation of the mill, whereby the rags and the liquid are caused to pass between the rotating rods to separate the fibers and the rags and to form a fibrous feltable pulp.

3. The method of making felted sheets com-,

prising moistening and beating a guantity of textile stock, refining the moistened. stock for a predetermined period of time between a plurality of rods rolling over and in contact with each other, subjecting the refined stock to the action of a finish beater, and felting the stock into a sheet.

4. The method of making a felted sheet comprising feeding a quantity of stock to a beater, beating the stock in the presence of water, removing the water to leave the stock in a moistened condition, refining the moistened stock between a bundle of loosely mounted rolls, feeding the refined stock to a finish beater, and felting the stockinto a sheet. I

5. Themethod of making a felted sheet comprising feeding a quantity of fibrous stock and water to a beater, beating the stock in the presence of the water until same is thoroughly saturated, removing the excess water to leave the stock in a moistened or saturated condition, refining the moistened stock between a bundle of loosely mounted rods containing rolls of varying diameters, feeding the refined stock to a finish beater in the presence of an added-supply of water, and felting the stock into a sheet.

6.- The method of making a felted sheet comprising beating a quantity of textile material and feeding same to a container having disposed therein a bundle of loosely mounted rods, actuating the container for causing the rods to draw out the fibers, and felting the refined stock into a sheet. x

7. The method of making a felted sheet comprising beating a quantity of textile material and feeding same to a rotating container having disposed therein a plurality of loose rods ar-' ranged parallel to the longitudinal axis of the container, actuating the container to rotate same and thereby cause the rods toroll over each other while the fibrous stock is passed between them to separate the fibers without materially reducing their length, and felting the refined stock into a sheet.

8. The method of making a felted sheet comprising cutting fibrous stock into small pieces,

, beating the cut stock in the presence of water,

removing the excess water to leave the beaten stock in a moistened condition, refining the moistened stock between a bundle of loosely mounted rods, beating the refined stock in the presenceof w an added supply of water, and'felting the stock into a sheet.

9. The method of making a felted sheet comprising cutting fibrous stock into small pieces, beating the stock in the presenceof water, removing excess water to leave the beaten stock in a-moistened condition, refining the moistened stock between a bundle of loosely mounted rods, beating the refined stock in the presence of an added supply of water, subjecting the stock to a Jordan engine and felting the stock into a sheet.

10. The method of making a felted sheet comprising beating stock in the presence of ,water, removing excess water to leave the beaten stock in a moistened condition, refining the moistened stock between a bundle of loosely mounted rods, beating the refined stock in the presence of an added supply of water, subjecting the stock to a Jordan engine and felting the stock into a sheet.

11. The method of making felted sheets comprising moistening and beating a quantity of textile stock, refining the moistened stock for a predetermined period of time between a plurality of rods rolling over and in contact with each other and felting the refined stock into a sheet.

12. The method of making felted sheets comprising moistening and beating a quantity of textile stock in the presence of water, removing the water to leave the stock in a ,moistened condition, refining the moistened stock for a predetermined period of time between a plurality of" rods rolling over and in contact with each other and felting the refined stock into a sheet.

13. The method of making felted sheets comprising moistening and beating a quantity of textile stock in the presence of water, removing the water to leave the stock in a moistened condition, refining the moistened stock for a predetermined period of time between a plurality'of rods rolling over and in contact with each other,

subjecting the refined stock'to the action of a continuous beater, and felting the refined stock into asheet.

14. An apparatus for making a felted sheet comprising a' beater adapted to receive the stock and beat same in the presence of water, means for removing the water to leave the stock in a moistened condition, means for treating the said beaten stock of water and fibrous containing material to separate the fibers' without materially reducing their length, and means for forming the stock into a sheet, said means "for treating the moistened stock comprising a rotating container having disposed therein a plurality of lodse rods adapted to roll over each other when the container is rotated.

15. An apparatus'for making a felted sheet for removing the water to leave the stock in a moistened condition, means for treating the said beaten stock of water and fibrous containing material to separate the fibers without materially reducing their length, means for subjecting the stock to a further beating action, and means for forming the stock into a sheet, said means for treating the moistened stock comprising arotating container having disposed therein a plurality of loose rods adapted to roll over each other when the container is rotated.

16. An apparatus for making a felted sheet comprising a beater adapted to receive the stock and beat same in the presence of water, means for treating the said beaten stock of water and fibrous containing material to separate the fibers without materially reducing their length, means. for subjecting the stock to a further beating acstantially uniform in size and character, and felting the pulp into a highly porous sheet.

18. A method of fabricating felt comprisgig subjecting rag scrap material to a beating operation, rolling the beaten material in the presence of a fiuid between a series of loose rollersfor separating the fibers to reduce said material to a ence of a fluid between a series of loose rollers for separating the fibers to reduce said material to a pulp in which a majority of the fibers are not reduced in length and are substantially uniform in size and character, and felting the pulp into 5 a highly porous sheet.

" WILLIAM A. SLA'I'I'ERY.

HENRY A. ELLIS. 

